Pre-heating contiguous in-line water heater

ABSTRACT

An improved pre-heating, contiguous in-line water heater is described. The in-line water heater utilizes a passive heating means to passively heat at least a portion of the input water received by the in-line water heater. The result is a more cost efficient water heater. The in-line water heater is integrated with a means for control to receive input from at least one sensor and to regulate the operation of the in-line water heater.

The instant application claims the benefit of and priority to U.S. patent application Ser. No. 10/365,072, filed Feb. 12, 2003, U.S. provisional application Nos. 60/526,352 and 60/526,333, both filed on Dec. 2, 2003. The instant disclosure generally concerns water heaters. Specifically, the instant disclosure concerns pre-heating, in-line water heaters.

FIELD OF THE DISCLOSURE Background

In-line water heaters (sometimes referred to as on-demand water heaters) are designed to heat a continuous supply of input water only when hot water is demanded by a user. This is in contrast to typical storage tank water heaters which keep, on the average, 30-70 gallons of water heated and ready for use 24 hours a day. Opening a hot water faucet triggers one or more heating units (typically, either electric or gas) to heat the water as it flows through the in-line water heater. The water takes a circuitous path through tubing in the in-line water heater so the heating units of the in-line heater have an opportunity to heat the water sufficiently. With in-line water heaters, there is never a shortage of hot water since there is never a tank to deplete. In addition, since there is no tank to heat continuously, there is a significant energy savings.

A conventional in-line water heater comprises a water input to allow water from the plumbing system to enter the water heater, a water output to distribute hot water for use, and a series of transit channels, or heating chambers, to direct the water through the in-line water heater. In many cases, these heating chambers are arranged in a baffle like arrangement which requires the water to travel an extended distance in the in-line water heater. These systems also comprise a means for flow detection which is triggered when hot water is demanded from the system. The means for flow detection may be a device known in the art or one described herein. The flow detection device may be linked to a control circuit or means for control. The flow detection device signals the means for control that water is flowing through the system. The means for control then triggers one or more heating units (typically, either electric or gas) to heat the water as it flows through the in-line water heater.

In many cases the means for flow detection and the means for control form an energy saving device, limiting the heating of water to times when water is flowing through the system. A number of flow detection devices have been described. They include pressure responsive controllers, mechanical distributing systems responsive to differences in pressure, or complex electromagnetic devices. However, the art is lacking a simple, economical flow detection device that is specifically designed for use with liquid handling systems, such as water heaters.

The present disclosure describes an in-line water heater comprising one or more of several unique elements which result in a more efficient water heater than was heretofore appreciated in the field.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows a perspective view of one embodiment of the in-line water heater.

FIG. 2 shows a side view of one embodiment of the in-line water heater illustrated in FIG. 1.

FIG. 3 shows a top view illustrating the internal arrangement of one embodiment of the in line-water heater illustrated in FIG. 1.

FIG. 4 shows a top view illustrating the internal arrangement of an alternate embodiment of the in line-water heater.

FIG. 5 shows an alternate embodiment of the in-line water heater.

FIG. 6 shows a side view of an alternate embodiment of the in-line water heater of the present disclosure illustrating a single, continuous transit channel.

FIG. 7 shows another alternate embodiment of the in-line water heater illustrating pre-heating of the input water.

FIG. 8A shows one embodiment of an enclosure for the in-line water heater and its components.

FIG. 8B shows an additional view of one embodiment of an enclosure for the in-line water heater and its components.

FIG. 9 shows an exploded view of one embodiment of the flow detection device described herein.

FIG. 10A shows a cross sectional view of one embodiment of the flow detection device in the off state.

FIG. 10B shows a cross sectional view of one embodiment of the flow detection device in the on state.

FIG. 10C shows a cross sectional view of an alternate embodiment of the flow detection device in the on state.

FIG. 11 shows one embodiment of the design of a chip of the present disclosure.

DETAILED DESCRIPTION

The present disclosure describes a pre-heating, contiguous in-line water heater. The in-line water heater described comprises a number of unique components (each of which may be used alone or in various combinations), such as, but not limited to, a passive heating means, an improved flow detection device and an improved power transformer unit. A means for control for controlling the in-line water heater and encasement for the in-line water heater are also described.

In-Line Water Heater

As with conventional water heaters, cold water is fed into the in-line water heater (input water) heated as it travels through the in-line water heater. The in-line water heater described herein has several embodiments. The in-line water heater is described as being used with water, however, it should be understood that the in-line water heater can be used with other liquids as well, if desired. The embodiments described below are given for the purpose of example only such that one of ordinary skill in the art may understand the scope and content of the disclosure and is not meant to preclude other embodiments from the scope of the disclosure.

FIG. 1 shows a perspective view of the in-line water heater of the present disclosure. The in-line water heater 1 comprises a body 2. In one embodiment, the in-line water heater 1 further comprises a top cap 4 and a bottom cap 6 to house various control and sensory components (as described herein below). In an alternate embodiment, the control and regulatory elements may be separated from the in-line water heater 1 (as described herein below). In one embodiment, the body 2 is generally cylindrical in form. However, the shape of the in-line water heater 1 may be varied as desired, with the cylindrical form being shown for exemplary purposes only. For example, FIG. 5 shows a body 2A of generally rectangular form. Other forms may also be used as desired. The body 2 comprises an outer periphery that at least partially defines an interior 50. The internal arrangement within interior 50 of body 2 may take on a number of forms. In its most basic form, the interior 50 of body 2 contains at least one transit channel to conduct input water from the cold water input 8 to the hot water output 10. There may be multiple transit channels which are interconnected, or there may be a single continuous transit channel (as illustrated in FIG. 6) within the interior 50. All or less than all of the transit channels may contain a heating element to heat the input water as it travels through the in-line water heater 1. The interior 50 may further comprise a passive heating means. The function of the passive heating means is to transfer a portion of the heat generated by the in-line water heater to other sections of the in-line water heater and/or to retain heat in the nature of a heat sink. The heat transferred may be generated by the heating elements, for example. The passive heating means may comprise a variety of materials, such as, but not limited to, insulating foam, Styrofoam, asbestos, glass fiber insulation, metal, stone and sand. The metal may be a variety of metals included but not limited to, copper, a copper alloy, aluminum, an aluminum alloy, tin or a tin alloy, brass or a brass alloy, a combination of the foregoing, or any other metal that is capable of conducting heat and/or to retain heat in the nature of a heat sink. The interior 50 may be hollow or the interior 50 may be solid. When the interior 50 is solid, the solid acts as the passive heating means and the at least one transit tube may be cast within the solid interior. When the interior 50 is hollow particulate matter (as described above) acts as the passive heating means and the transit tubes may be surrounded with the particulate matter.

So that one of ordinary skill in the art may understand the workings of in-line water heater 1, reference is made to the specific embodiments illustrated in the figures. As shown in FIG. 1, the interior 50 of body 2 is cast from a solid material. In this embodiment, the solid interior 50 serves as the passive heating means. FIG. 1 shows 4 interconnected transit channels labeled 11, 12, 13 and 14, which are cast in the solid interior 50. However, fewer or greater number of transit tube may be used. For example, FIG. 5 shows an embodiment of the in-line water heater 1 comprising two transit channels, 11A and 12A. FIG. 6 shows an embodiment comprising a single continuous transit channel 15. These transit channels may be created in the casting process as hollow cavities within the solid interior 50. The transit channels 11-14 are interconnected with one another (as shown in FIG. 3 and discussed below). Furthermore, at least one of the transit channels is connected to the cold water input 8 and at least one of the transit channels is connected to the hot water output 10. The connections may be made by standard techniques known to one of ordinary skill in the art. In the embodiment illustrated in FIG. 1, transit pipe 11 is connected to cold water input 8 and transit pipe 14 is connected to hot water output 10.

One or more of the transit channels may contain a heating element 18 as shown in FIG. 1. FIG. 1 shows 3 heating elements 18, but each of the transit channels 11-14 may contain a heating element (as illustrated in FIG. 5, where transit channels 11A and 12A each contain a heating element 18). The purpose of the heating element is to heat the input water as it flows through the transit channels. The transit channels 11-14 may not extend all the way to the top portion 44 of solid interior 50 and may terminate slightly below the top portion 44 to produce a recess 46 to receive the heating element 18. The heating element 18 and the recess 46 may further comprise complementary male and female threads to removably secure the heating element 18 into the recess 46. The recess 46 may also contain a sealing means, such as a gasket or O-ring. The heating elements 18 may be in communication with a means for control as discussed below. Briefly, the means for control receives input from various sensors and heating elements positioned in the in-line water heater 1 and controls the activation of the individual heating elements 18, among other things.

The number of heating elements 18 and or transit channels used will depend on the volume of water to be heated by the in-line water heater 1. Referring to the embodiment illustrated in FIG. 1, for a typical residential setting, three heating elements 18 and 4 transit channels 11-14 will generally provide sufficient quantities of hot water for use. When less than all of the transit channels 11-14 contain a heating element 18, it is preferred that the transit tube connected to the cold water input 8 not contain a heating element (transit tube 11 in this example). Once the heating elements 18 are activated by the means for control as discussed below, the heating elements 18 will rapidly heat the solid interior 50 (or the particulate matter if the interior 50 is hollow) of the in-line water heater 1 via transduction of heat by the passive heating means. This will create conditions where the water flowing through transit tube 11 will be heated by the interior 50 of the in-line water heater 1 (referred to as “passive heating”). The use of passive heating allows additional heating of the water flowing through the in-line water heater 1 without the expenditure of additional energy and contributes to the efficiency of the unit. In initial studies the water is heated an average of 4-6 degrees Fahrenheit (F) as it travels up transit pipe 11 (from an input temperature of 56 degrees F. to 60-62 degrees F.). This passive heating of the water occurs at no added energy expense to the system. The passive heating allows the water to be heated to the set temperature in a shorter time. In essence, the energy efficient design of the instant in-line water heater 1 allows a head start on the heating process at no added energy expense.

In commercial applications, each of the transit channels 11-14 may contain a eating element 18. Other factors that may influence the number of heating elements and/or transit channels to be incorporated include the climate of the area where the in-line water heater 1 is used. In temperate climates, three or fewer heating elements may be incorporated into the in-line water heater for use in a residential setting. In colder climates, four heating elements may be required to provide sufficient quantities of hot water. In addition, more transit channels could be incorporated into the in-line water heater 1 and used with or without heating elements 18. The size of the structure may also influence the number of heating elements used and/or the number of transit channels used. For larger structures, more heating elements and/or transit channels may be used as discussed above. Furthermore, the desired output temperature of the water may also influence the number of heating elements and transit channels used. Alternatively, more than one in-line water heater may be used to generate additional quantities of hot water.

FIGS. 2, 3 and 4 illustrate examples of the flow of water through the in-line water heater 1. With reference to FIG. 3, input water (as normally supplied by standard systems) enters the in-line water heater 1 through the cold water input 8. The water travels up transit pipe 11. During the movement up transit pipe 11, the water is heated either passively as discussed above or via a heating element 18 which is in communication with the input water. The water reaches the top of transit pipe 11 and passes through connecting pipe 30A and travels down transit pipe 12 where it flows through connecting pipe 30B into transit pipe 13. The water flows up transit pipe 13, through connecting pipe 30C into transit pipe 14. The water flows down transit pipe 14 and out of the in-line water heater 1 through hot water output 10. The hot water is then distributed for use via standard feed pipes. As the water flows through transit channels 12-14 the water may be heated by heating elements 18, which are in communication with the water when present. In addition, the water undergoes additional passive heating as described.

An alternate embodiment of the in-line water heater 1 is shown in FIG. 4. Referring to FIG. 4, in this embodiment, there are 4 transit channels and the cold water input and hot water output are connected to transit tubes which extend into the interior 50 of the in-line water heater 1. In this embodiment, the cold water input and hot water output extend to just below the top portion 44. The cold water enters through transit pipe 110 which is connected to the cold water input (not shown). The water travels up transit tube 110 through connecting tube 112A into transit tube 102. The water travels down transit tube 102, through connecting tube 112B and up transit tube 104, through connecting tube 112C, down transit tube 106, through connecting tube 112D, up transit tube 108, through connecting tube 112E and down transit tube 114. The water exits transit tube 114 through the hot water output (not shown). In this embodiment, the transit channels 110 and 114 do not contain heating elements 118, although in an alternate embodiment heating elements could be used (as might be the case if it was desired to increase heating capacity). Instead, the water flowing through transit channels 110 and 114 is passively heated by the proximity to transit channels containing heating elements and via heat conducted by the passive heating means (in this embodiment solid interior 50). In an alternate embodiment, the passive heating means could be any one of the materials described above. In an alternate embodiment, the cold water may enter directly through transit tube 11 as illustrated in FIG. 3 and proceed through the system as described above. However, instead of exiting through transit tube 11 as described in FIG. 3, the input water may flow through a connecting pipe, such as 112E in FIG. 4 and exit the in-line water heater through transit tube 114 which is connected to the hot water output (not shown).

Referring to FIGS. 1, 3 and 4, the body 2 may have an outer covering 40 covering the solid interior 50. The outer covering 40 is optional, and functions to allow a user to handle the in-line water heater 1 when the unit is in operation. The outer covering 40 may be constructed of a variety of materials, including, but not limited to, various polymers (such as PVC), various plastics or metals (such as stainless steel). There may also be a layer of insulation between the outer covering 40 and the solid interior 50 (shown as 42 in FIGS. 1, 3 and 4).

An additional alternate embodiment of the in-line water heater 1 is described below and shown in FIG. 7. The basic concepts of the operation of the in-line water heater 1 remain the same as described above. In this embodiment, the input water for the in-line water heater is not drawn directly from the water normally supplied to the structure. Instead, the water is drawn from an intermediary holding tank 60. The water in the intermediary holding tank may be heated before being delivered to the in-line water heater 1. The heating may be by any means, such as gas or electric. Alternatively, the tank may not be directly heated, but may be heated by solar energy 64 through the use of solar panels 62 or other means. The temperature of the intermediary holding tank will ideally be above that of the water that would otherwise be supplied to the in-line water heater 1.

Means for Control, Detecting Devices and Monitoring Devices

The in-line water heater may further comprise certain accessory elements, such as, but not limited to, connecting means for standard electrical connections for use with residential housing and commercial structures, various sensors, monitoring devices and a means for control. In one embodiment, the connecting means and means for control are contained in a top cap 4, a bottom cap 6 or a combination thereof. In one embodiment, the top cap 4 contains the connecting means and the means for control and is divided into two sections, one containing the connecting means (i.e electrical connections) and one containing the means for control. The means for control may be in communication with the various sensors and monitoring devices as disclosed below. The bottom cap 6 functions to contain certain regulatory and sensing devices and to cover the bottom of the in-line water heater 1. The bottom cap 6 may have openings therein to receive the cold water input 8 and the hot water output 10. In addition, the bottom cap 6 may comprise a drain 24. The bottom of bottom cap 6 may be concave to allow the collection and drainage of water that may escape from the in-line water heater 1. As discussed below, the leak detecting means 22 may be placed near the drain 24.

The top cap 4 and bottom cap 6 are adapted with an engagement means to securely and reversible engage the body 2. The engagement means may employ a snap/friction fit, one or more hinges, the use of complementary male and female threads on the top cap 4 and/or bottom cap 6 and the body 2, a combination of the above, or other commonly used means. In addition, there may be a gasket or other sealing means to separate the contents of the top cap 4 from the body 2. Since the top 4 and bottom 6 caps are removable, the system may be easily accessed for maintenance and repair. For example, if the means for control indicated that a heating element is not functioning properly (either by a visual alarm, an audible alarm or both as discussed below), the top cap 4 may be removed. The LED display would indicate which heating element was not functioning correctly. The suspect heating element could then be removed by simply unscrewing the heating element and replacing the heating element with a new one if required.

In an alternate embodiment, the accessory elements, such as, but not limited to, connecting means for standard electrical connections for use with residential housing and commercial structures, various sensors, monitoring devices and a means for control may be separated from the in-line water heater 1. As illustrated in FIGS. 8A and 8B, in-line water heater 1 may be contained in an enclosure 150. The enclosure 150 is designed to contain the in-line water heater 1 and the accessory components and protect the same from inadvertent damage. The enclosure 150 may take a variety of forms as is known in the art. In one embodiment, the enclosure 150 comprises a base 152, a cover 154, a panel 156 and an electrical conduit 158. The base 152 is divided into 2 sections, 160 and 162. As illustrated, section 160 contains the in-line water heater 1 and section 162 contains the accessory elements. Sections 160 and 162 are separated by divider 164. Section 162 may contain a variety of accessory components as desired. In the embodiment illustrated, section 162 contains the means for control 170, a visual display 172, inputs 173 to provide adjustments to the parameters discussed below and the connecting means (electrical connections) 174. The connecting means provides power to the heating elements. The connecting means is illustrated with breakers as shown and may contain other standard features known in the art. The means for control 170 is in communication with the visual display 172 and inputs 173 via connection 178. The means for control may be connected to the standard electrical supply for the structure or may contain a battery or similar internal power supply. In the event power is supplied by the electrical supply for the structure, a novel transformer replacement chip set (not shown, as discussed below and illustrated in FIG. 11 may be used). The means for control may be in communication with the various sensors and monitoring devices as disclosed below (shown via connections 176). The embodiment of enclosure 150 is exemplary alone, and may contain additional elements, and further, the embodiments shown may be arranged in alternate configurations.

Panel 156 covers and further isolate the contents of section 162. Panel 156 may have openings to receive the visual display 172, the inputs 17 and connecting means 174. Cover 154 covers both section 160 and section 162 and allows easy access to the components of each section.

Means for Control

The means for control comprises electronics monitoring and regulating components. The connecting means are electrical connections are those that are commonly used in the field and are well know to those of skill in the art. The means for control also comprises standard components, the operation and arrangement of which are well known to those of skill in the art. The means for control is in communication with the various sensors and monitoring devices described below and is also in communication with the heating elements. The means for control may contain a processing unit with sufficient memory and capacity to execute the functions described.

The means for control is capable of performing a number of self-monitoring and self-regulating functions regarding the in-line water heater. These functions include, but are not limited to: 1) monitoring the temperature of the input water as it travels through the in-line water heater; 2) monitoring the heating elements to determine which elements are in use at a given time; 3) providing an input means to set the temperature of the input water to a desired level (referred to as the “set temperature”); 4) determining how many of the heating elements are required to heat the input water to the set temperature and controlling the activation of said heating elements to achieve such heating; 5) monitoring the heating elements to determine which elements are functioning properly; 6) monitoring the system for free water, such as may occur from leaks; 7) monitoring the flow of input water through the system and activating at least one heating element when a flow is detected; 8) alerting the user when the in-line water heater is not functioning within a first set of parameters, such as detection of a leak, detection of a heating element that is not functioning properly, detection of a blockage in the transit channels and detection of an inability to heat said input water to the set temperature; and 9) providing the user of a visual display of a second set of parameter, such as the set temperature, the presence of a leak, the status of each of the heating elements, the current temperature of the input and/or output water and whether the in-line water heater is currently being supplied with power. Other functions that are used in water heaters as are currently known in the art may also be incorporated into the means for control.

The visual display may be any means to visually inform the user of a desired aspect of the in-line water heater. For example, the visual display may be a LED display. The LED display may give the information in any convenient format. For example, the LED display may give the set temperature in a numeric readout and inform the user regarding the status of the heating elements through the use of individual display elements representing each heating element in the in-line water heater. If a heating element was in operation, a display element may be illuminated, or illuminated in a first color. If the heating element is not operating correctly, the display element may be illuminated in a second color. Such display element may simply be a circular LED, or may be graphical in nature.

In addition to a visual display, the in-line water heater may comprise an alarm to alert the user when the in-line water heater is not functioning within established parameters, such as when a leak is detected, when a heating element is not functioning properly, when a block is detected in the transit channels or when the heating elements in operation cannot supply input water at the set temperature for sustained periods of time. For example, if the in-line water heater is not able to generate water meeting the set temperature requirement, an alarm may be generated. In addition, an alarm may be generated when one of the heating elements fails to function properly. Any aspect of the functioning of the means for control may be linked to an alarm. The methods for linking such functions to an alarm are known to those of skill in the art. The alarm may be an audible alarm, a visual alarm or a combination of a audible alarm or a visual alarm.

Flow Detection

The means for control may receive signals from a means for flow detection. The means for flow detection is in fluid communication with the water input into the in-line water heater. The means for flow detection may be a flow detector. The flow detector may be any such detector that is known in the art. In one embodiment, the flow detector comprises the unique design disclosed below. The integration of flow detectors as described is within the ordinary skill in the art. The means for flow detection would signal the means for control when water was flowing thought the in-line water heater. The signal would cause the means for control to activate a sufficient number of heating elements in order to heat the input water to the set temperature. In some cases all of the heating elements may be activated and in some cases less than all of the heating elements may be activated. Location of the flow detecting means may be any position where the flow detecting means has access to determine the flow of water through the system. In one embodiment, the flow detecting means is located in conjunction with cold water input 8. In an alternate embodiment, the flow detecting means is located in conjunction with hot water output pipe 10. In other embodiments, the flow detecting means may be placed inside or in conjunction with transit tubes (such as transit tubes 11-14 in FIG. 1).

One embodiment of the means for flow detection is the flow detector illustrated in FIGS. 10A-C. The flow detector is labeled generally as 200. The flow detection device 200 may be placed in any one or more of the transit tubes of the in-line water heater 1, such as transit tubes 11-14 of FIG. 1. The flow detection device 200 is operational in a number of orientations due to the unique design of the device. In one embodiment, the flow detection device is placed in a position so that the axis of the flow detection device, labeled as A in FIG. 10A, is in a perpendicular position. In an alternate embodiment, the flow detection device 200 is placed in a position so that the axis A of the flow detection device is in a horizontal position. Intermediate orientations for the flow detection device 200 between perpendicular and horizontal may also be used as dictated by the design of the system with which the flow detection device is used.

FIG. 10A illustrates the flow detection device 200 as used in an in-line water heater. As illustrated the flow detection device is placed in a transit pipe, designated 212, that carries water through the in-line water heater. Connecting pipe 214 is illustrated connecting to transit pipe 212. In one embodiment, the flow detection device comprises a means for anchoring, a magnetic means for signal generation and a means for detection of said signal. In the embodiment illustrated in FIG. 10A, the means for anchoring is illustrated as support post 216. Support post 216 is secured in the transit pipe 212. FIG. 10A illustrates support post 216 being secured to the floor 218 of transit tube 212. The post 216 receives the magnetic means for signal generation. The magnetic means for signal generation is illustrated as a magnetic element 220. Magnetic element 220 is movably received on support post 216. In one embodiment, magnetic element 220 is slidably received on support post 216 such that the magnetic element 220 is capable of movement up and down the length of support post 216. In one embodiment, the magnetic element 220 is bordered by first and second bounding magnetic elements, illustrated as 222 and 224, respectively. The first and second bounding magnetic elements serve to limit the travel of magnetic element 220 and limit the impact of the magnetic element 220 with portions of the support post 216. In the embodiment illustrated, the first and second bounding magnetic elements 222 and 224 are placed at the top and bottom of support post 216, however other placements may be used. The first and second bounding magnetic elements 222 and 224 are secured to the support post 216. FIG. 10A also illustrates spacers 226 flanking the second bounding magnetic element

The polarity of the magnetic element 220 and the first and second bounding magnetic elements 222 and 224 are arranged such that like poles of the magnetic element 220 and the first and second bounding magnetic elements 222 and 224 are placed in juxtaposition to one another. In other words, the south magnetic pole of magnetic element 220 and the south pole of the first bounding magnetic element 222 are placed in juxtaposition to one another thereby creating a magnetic repulsion that keeps the magnetic element 220 suspended above the first bounding magnetic element 222. A similar situation occurs between the north magnetic pole of magnetic element 220 and the north magnetic pole of the second bounding magnetic element 224. As a result, the magnetic element 220 is capable of responding to small changes in water flow through the system by movement along post 216.

A means for focusing, illustrated as reducer 228, may be used in combination with the flow detection device 200. The means for focusing, when used, serves to channel the flow of water toward the magnetic element 220. The means for focusing may be helpful in certain applications where minimal/low water flow is to be determined. The reducer 228, when used, is secured within the inner diameter of transit pipe 212. The reducer 228 comprises a neck 230 and outwardly extending flanges 232. The inner diameter of the neck 230 may be sufficient to reversible receive the magnetic element 220, thereby allowing the magnetic element 220 to pass through the neck 230. In an alternate embodiment the inner diameter of the neck 230 may be such that the magnetic element 220 cannot pass through neck 230, the neck 230 thereby serving as a lower stop for the magnetic element 220. In this alternate embodiment, the second bounding magnetic element 224 and spacers 226 may be omitted if desired.

The magnetic element 220 inherently produces a magnetic field, illustrated as 250 in FIGS. 10A-C as is known in the art. The magnetic field 250 serves as the signal to be detected by the means for detection. The means for detection is illustrated as sensor 234. The means for detection is in communication with a means for control to receive signals generated by the means for detection. The means for control utilizes the input from the means for detection to regulate the operation of the in-line water heater. In this manner, the desired operational parameters of the in-line water heater may be regulated.

The operation of the flow detection device 200 is illustrated in FIGS. 10A-C. In FIG. 10A, the flow detection device is shown in the absence of water flow (referred to as the off state). In the off state, the magnetic element 220 rests above the second bounding magnetic element 224 as a result of the magnetic repulsion between the like poles of these elements. In this embodiment, the repulsion places the magnetic element 220 in the neck 230 of reducer 228. In this position the signal (magnetic field 250) produced by magnetic element 220 will not be read by the means for detection (sensor 234). The means for detection either transmits input to the means for control periodically that no signal is being detected (i.e., no water is flowing through the system), or the absence of an input transmitted from the means for detection is interpreted by the means for control that no water is flowing through the system. The means for control takes appropriate action to regulate the appropriate operational parameters of the in-line water heater based on the input from the means for detection.

In FIG. 10B the flow detection device is shown in the presence of water flow (referred to as the on state). As water flows through transit pipe 212, the water urges the magnetic element 220 up the support post 216. As the magnetic element 220 travels up the support post 216, the signal (magnetic field 250) produced by the magnetic element 220 is read by the means for detection (sensor 234). Although FIGS. 10A and 10B illustrate the use of reducer 228, the use of reducer 228 is optional (as is also the case for FIG. 10C discussed below). The signal detected by the means for detection is transmitted to the means for control. The means for control takes appropriate action to regulate the appropriate operational parameters of the in-line water heater based on the input from the means for detection.

The flow detection device 200 is capable of determining when water is flowing through the in-line water heater, the flow rate of the water flowing through the in-line water heater, or both. In one embodiment, the flow detection device detects the presence or absence of water flowing through the in-line water heater and transmits appropriate input to the means for control (referred to as “on/off detection”). In on/off detection, either water flow is detected or water flow is not detected and the means for control takes appropriate action to regulate the appropriate operational parameters of the in-line water heater based on the input from the means for detection. In an alternate embodiment, the flow detection device detects the presence or absence of water flowing through the in-line water heater and further determines the flow rate of said water flowing through the in-line water heater and transmits appropriate input to the means for control (referred to as “flow detection”). In flow detection, the flow rate of the water flowing through the system is determined and the means for control takes appropriate action to regulate the appropriate operational parameters of the in-line water heater based on the input from the means for detection.

The means for detection can be calibrated to respond to predetermined levels of the magnetic field 250 (i.e., the signal generated by magnetic element 220). In one embodiment, the means for detection can be appropriately calibrated so that the signal (the magnetic field 250) detected is transmitted to the means for control only when a predetermined threshold volume of water is flowing through the in-line water heater. Alternatively, the means for detection can be appropriately calibrated so that the means for detection senses the strength of the signal (the magnetic field 250) generated by the magnetic element 220 and transmits input to the means for control as to the volume of water flowing through the in-line water heater.

In an alternate embodiment, the flow detection device 200B can incorporate a magnetic element which is not sildably connected to support post 216, indicated as magnetic element 220B in FIG. 10C. In this alternate embodiment, the magnetic element is capable of rotational movement in response to the flow of water through the system. In one form of the alternate embodiment, the magnetic element 220B is a magnet embedded in at least one blade of a propeller (indicated as 260 in FIG. 10C). As water flows past the propeller blades, the propeller blades, along with the at least one attached magnetic element 220B, rotate. The rotation produces a variation in the magnetic field produced by the at least one magnetic element 220B that is detected by the means for detection as described above. As is discussed above, the alternate embodiment of the flow detection device can be used for on/off detection as well as for flow detection.

A variety of means for detection can be employed as are known in the art. In one embodiment, the means for detection employs a Hall effect sensor. The principles and operation of Hall effect sensors, as well as their integration with various circuits, is well known in the art. The means for detection may be placed at any location convenient for detection of the signal generated by the magnetic element 220 or 220B. In one embodiment, the means for detection is placed on the exterior of the transit pipe 212. The means for detection can be hard-wired to the means for control or can transmit the signal(s) to the means for control by wireless technology.

Temperature Detection

In addition to monitoring the flow of water through the system, the in-line water heater described can also monitor the temperature of the input and output water through the use of means for temperature detection. The means for temperature detection is in fluid communication with the water input into the in-line water heater. Alternatively, the means for temperature detection may be in communication with the exterior of the transit channels and be calibrated to determine the temperature of the water from the temperature of the transit channels. The means for temperature detection may be temperature sensors as are common in the field. The operation and integration of means for temperature detection as described is within the ordinary skill in the art. As with the flow detecting means, the means for temperature detection may be positioned at any position where the means for temperature detection has access to the water flowing through the system. In one embodiment the means for temperature detection are located in conjunction with hot water outlet pipe 10.

There may be multiple means for temperature detection to monitor the temperature of the water at various stage of transit through the in-line water heater. FIG. 1 shows the placement of temperature sensors 54 and 56 on the input 8 and output 10 pipes. However, means for temperature detection may be placed in other locations as well. In one embodiment, the means for control compares the temperature of the output water to the set temperature and determines the difference between the two. If this difference is large, then the means for control activates all available heating elements. This may occur when the flow detecting means first detects a flow of water through the system. As the difference becomes smaller, then the means for control may inactivate one or more heating elements. The means for control can be set to respond as desired to a range of differences between the temperature of the output water and the set temperature. In one embodiment where three heating elements are present, when the difference is at least 25 degrees F., all three heating elements are activated. When the difference is between 24 and 10 degrees F., then two heating elements are activated. When the difference is between 9 and 1 degrees F., then only one heating element is activated. Finally, when the temperature of the output water is equal to or greater than the set temperature, no heating elements are activated. Other temperature parameters may be selected with the above parameters being exemplary only.

Leak Detection

The in-line water heater may also contain a means for leak detection. The means for leak detection may be a sensor capable of sensing the presence of free water in the system. The operation and integration of the leak detecting means as described is within the ordinary skill in the art. The means for leak detection may be located at any desired location, but in one embodiment the leak detection (illustrated as 22 in FIG. 1) is located near the drain 24 in bottom cap 6. If the means for leak detection senses free water, then the means for leak detection may signal the means for control to sound an audible alarm and/or a visual alert to the user.

Replacement Transformer Chip Set

The present disclosure also describes a chip set designed for the replacement of a conventional transformer. The chip set described performs the operation of a conventional transformer, while eliminating certain drawbacks associated with the operation of conventional transformers. The chip set described decreases the input voltage (typically in the range of 220 to 240V) to the voltage required for the operation of standard electronic chip components (typically 5V) with generating excess amounts of heat which may cause damage to other components of the system. In addition, the chip set described is compact and economical to manufacture allowing for ease of installation and decreased production costs.

One embodiment of the chip set described is shown in FIG. 10. Other embodiments of the chip set may be envisioned by one of ordinary skill in the art, with the embodiment in FIG. 10 being shown for understanding of the chip set described herein. The input to the chip set is in one embodiment a standard 220 V alternating current. The components of the chip set convert the 220 V alternating current to an output of 5 V direct current. The components of the chip set comprise a series of resistors, diodes, capacitors and ground connections as illustrated in FIG. 10. Said components are arranged to provide the required output based on an input of 220 V of alternating current. If the input of alternating current is varied, the design of the chip set and the components thereof may be modified to achieve the required output of 5 V direct current. The 5 V direct current output can then be used by the means for control to carry out the operations required for the operation of the in-line water heater.

CONCLUSION

The in-line water heater describe is energy efficient in use for a number of reasons. First, the heating elements of the in-line water heater are only in use when water is flowing through the system. When the means for flow detection, such as the unique flow detector 200, does not detect a flow of water through the in-line water heater, the heating elements are maintained in an inactive state. The means for flow detection may be in communication with the means for control as described. Second, the in-line water heater is comprises a passive heating means constructed from materials that retain the heat produced by the heating elements and the heated water. As a result, the body of the in-line water heater serves to passively heat the water flowing through the system. In addition, the water that is contained in the in-line water heater will retain its heat for a longer period of time. Third, the means for control of the in-line water heater monitors the temperature of the output water and compares that temperature to the set temperature to determine how many of the heating elements are required to be in operation in order to maintain the temperature of the output water at the set temperature. If there is a large gap between the temperature of the output water and the set temperature, the means for control activates all available heating elements. As the gap becomes smaller fewer that all the heating elements are activated by the means for control.

It should be noted that the in-line water heater described herein incorporates certain standard features that are common on both in-line water heaters and/or storage tank water heaters. These features and their applicability to the in-line water heater described herein are within the ordinary skill in the art in the plumbing field and are not discussed in detail. Such features include those described above such as electrical connections, flow detecting means, means for temperature detection, leak detecting means, but also include features such as, but not limited to, relief valves and standard connecting elements and couplings.

The features of the new in-line water heater described herein are not meant to be an exhaustive listing of features, but only to provide a general idea of the operation of the system. Other features may be apparent to those of ordinary skill in the art. 

1. An in-line water heater for heating input water comprising: a. a body having an outer perimeter that partially defines an interior, said interior comprising at least one transit channel for transporting said input water through said water heater and a passive heating means; b. a water input in communication with a first end of said at least one transit channel to deliver said input water to said water heater and a water output in communication with a second end of said at least one transit channel to distribute said water to at least one feeder pipe; c. at least one heating element in combination with said at least one transit channel, said heating element being in communication with and heating said input water; and d. where at least a portion of said input water is passively heated by a transfer of heat from said passive heating means to said input water.
 2. The water heater of claim 1 where the passive heating means is selected from the group consisting of insulating foam, Styrofoam, asbestos, glass fiber insulation, metal, stone and sand.
 3. The water heater of claim 2 where the metal is selected from the group consisting of copper, aluminum, brass, tin and alloys thereof.
 4. The water heater of claim 1 where said passive heating means is a solid metal and the at least one transit channel is cast within said solid metal.
 5. The water heater of claim 1 where the at least one transit channel is a single transit channel.
 6. The water heater of claim 1 where the interior comprises at least four interconnected transit channels and not more than three heating elements in combination with said transit channels.
 7. The water heater of claim 6 where the transit channel in communication with said water input does not contain a heating element.
 8. The water heater of claim 6 where the interior comprises not more than 4 heating elements.
 9. The water heater of claim 1 where at least one of the water input or water output extend into said interior.
 10. The water heater of claim 9 where said at least one of the water input or water output extend to an uppermost portion of said interior.
 11. The water heater of claim 10 where the degree of said passive heating is proportional to the length of said at least one of the water input or water output.
 12. The water heater of claim 9 where at least one of the water input or the water output is placed into proximity with said at least one transit channel to increase the efficiency of said passive heating.
 13. The water heater of claim 1 where said interior comprises at least four interconnected transit channels and not more than three heating elements in combination with said transit channels and where said water input and said water output extend to an uppermost portion of said interior.
 14. The water heater of claim 13 where the degree of said passive heating is proportional to the length of said water input and water output.
 15. The water heater of claim 13 where at least one of the water input or the water output is placed into proximity with at least one transit channel to increase the efficiency of said passive heating.
 16. The water heater of claim 1 where the input water is pre-heated before delivery to said water heater.
 17. The water heater of claim 16 where said pre-heating utilizes solar heating.
 18. The water heater of claim 1 further comprising an outer covering over the outer perimeter.
 19. The water heater of claim 18 where the outer covering is manufactured from a material selected from the group consisting of
 20. The water heater of claim 18 further comprising a layer of insulating material between the outer perimeter and the outer covering.
 21. The water heater of claim 1 where said water input further comprises a flow detecting means and said water output further comprises a means for temperature detection.
 22. The water heater of claim 1 further comprising a top cap and a bottom cap removably secured to said body.
 23. The water heater of claim 22 where said top cap contains a means for control and a connecting means and said bottom cap contains a leak detecting means and a drain.
 24. The water heater of claim 1 further comprising at least one sensor and a means for control in communication with said at least one heating element and said at least one sensor.
 25. The water heater of claim 24 where the at least one sensor is selected from the group consisting of a means for flow detection, a means for temperature detection and a leak detecting means.
 26. The water heater of claim 25 where the means for control performs at least one function selected from the group consisting of: 1) monitoring the temperature of said input water as said input water flows through said water heater; 2) monitoring said heating elements to determine which of said elements are in use at a given time; 3) providing an input means to set the set temperature; 4) determining how many of said heating elements are required heat said input water to the set temperature; 5) monitoring said heating elements to determine if said elements are functioning properly; 6) monitoring said water heater for a leak; 7) monitoring a flow of input water through said water heater and activating said heating elements only when said flow is detected; 8) alerting a user when said water heater is not functioning within a first set of parameters by activating an alarm; and 9) providing said user a visual display of a second set of parameters.
 27. The water heater of claim 26 where the alarm is a visual alarm, an audible alarms or a combination of a visual alarm and an audible alarm.
 28. The water heater of claim 26 where the first set of parameters include at least one parameter selected from the group consisting of: detection of a leak, detection of a heating element that is not functioning properly, detection of a blockage in the transit channels and detection of an inability to heat said input water to the set temperature.
 29. The water heater of claim 26 where the visual display is an LED display.
 30. The water heater of claim 26 where said second set of parameters include at least one parameter selected from the group consisting of: set temperature, current temperature of input water, on/off state of the heating elements; status of the individual heating elements and whether said water heater is receiving power.
 31. The water heater of claim 25 where the means for flow detection comprises: a. a means for anchoring secured to one of said at least one transit channel; b. a means for magnetic signal generation in communication with said input water, said means for magnetic signal generation being capable of generating a signal and being moveably secured to said means for anchoring so that the flow of said water changes a position of the means for magnetic signal generation and thereby the position of the signal; c. a means for detection of said signal wherein the means for detection transmits information to the means for control upon detection of said signal.
 32. The water heater of claim 31 where the means for magnetic signal generation is a magnetic element, the means for anchoring is a support post and the signal is a magnetic field.
 33. The water heater of claim 32 where the means for detection senses a change in the position of the magnetic field.
 34. The water heater of claim 32 where the magnetic element is slidably secured to the support post.
 35. The water heater of claim 32 where the magnetic element is rotatably secured to the support post.
 36. The water heater of claim 31 where the means for detection is a sensor, said sensor detecting said signal using the Hall effect.
 37. The water heater of claim 31 where means for control uses the information from the flow detection device to determine a flow parameter.
 38. The water heater of claim 37 where the flow parameter is selected from the group consisting of: the presence of the input water flowing through the in-line water heater, the absence of the input water flowing through the in-line water heater, the flow rate of the input water flowing through the in-line water heater, and a combination of the foregoing.
 39. The water heater of claim 38 where the determination of the flow parameter dictates how the means for control regulates an operational parameters of the in-line water heater.
 40. The water heater of claim 39 where the flow parameter is the presence of water flowing through the in-line water heater and the operational parameter is the activation of at least one heating element.
 41. The water heater of claim 39 where the flow parameter is the absence of water flowing through the system and the operational parameter is selected from the group consisting of: the deactivation of at least one heating element, the deactivation of all the heating element and the continued inactivation of all the heating element.
 42. The water heater of claim 39 where the flow parameter is the flow rate of the water flowing through the in-line water heater and the operational parameter is selected from the group consisting of: the activation of at least one heating element and the deactivation of at least one heating element.
 43. The water heater of claim 1 where the water heater is contained in an enclosure, said enclosure comprising a base, a left and right side wall, a top and bottom wall, and at least one divider creating at least 2 sections, a panel to cover at least one of said at least 2 sections and a cover, one of said sections to contain the water heater and one of said sections to contain a means for control, said means for control in communication with said at least one heating element and at least one sensor.
 44. The water heater of claim 43 where said panel further comprises a visual display in communication with the means for control and at least one input device.
 45. The water heater of claim 44 where the visual display a second set of parameters.
 46. The water heater of claim 45 where the second set of parameters includes at least one parameter selected from the group consisting of: set temperature, current temperature of input water, on/off state of the heating elements; status of the individual heating elements and whether said water heater is receiving power.
 47. The water heater of claim 43 where the section containing the means for control is water proof and the section containing the water heater contains a drain. 